Hull coverings

ABSTRACT

A product for the treatment of an area of an article residing underwater. The product is constituted by a plurality of shapes formed from copper or a copper nickel alloy and a carrier film. The product is adapted in use to be secured to the area of the article residing underwater such that the shapes contact or substantially contact each other. The shapes can be releasably secured to the carrier film or permanently secured to the carrier film. Suitable methods of applying the product to the area of the article are also disclosed.

[0001] The present invention relates to a treatment for areas ofarticles residing underwater, particularly the hulls of ships, toprovide protection from aquatic growths and borers.

[0002] Historically ships were built of wood, however there are aquaticorganisms and borers, such as Toredo worm and Gribble, that feed on thewood from which the ship hulls were built thus rendering the lives ofthe hulls short.

[0003] In the late 1700s copper sheathing was used to preventinfestation of wooden hulled ships by borers and it was soon realisedthat copper sheathing also prevented aquatic growths. However, coppersheathing could not be used on iron clad ships that were being developedaround this time as the copper accelerated the corrosion process of theiron and steel through galvanic action.

[0004] The development of antifouling paints for application to areas ofarticles residing underwater soon followed. Early antifouling paintsonly contained Cuprous-Oxide as the effective ingredient and theirperformance was poor. Later antifouling paints contained Cuprous-Oxide,Tin and Tri-Butyl-Tin compounds (TBTs) as the effective ingredientswhich provided an improved performance but lead to damage of aquaticlife such as shellfish stocks. The use of TBTs has now been banned onall craft under 25 metres.

[0005] In spite of the variety of antifouling paints available each hasassociated disadvantages in either its performance or effect on theenvironment. Furthermore to treat a ship hull, or any other article,with antifouling paint the ship must be removed from the water, theaquatic growth must be removed and the area to be painted must bescrubbed clean before the antifouling paint, which is both toxic tohumans and the environment, can be applied. This task is ideally carriedout every year and is time consuming and unpleasant and is alsostressful for articles such as ships as well as being expensive.

[0006] There remains a need for a treatment for areas of ships and otherarticles spending considerable time underwater that is effective, lastsfor more than one year and is generally environmentally friendly.

[0007] The present invention therefore provides a product for thetreatment of an area of an article residing underwater comprising aplurality of shapes formed from copper or a copper nickel alloy and acarrier film and adapted in use to be secured to the area of the articleresiding underwater such that the shapes contact or substantiallycontact each other.

[0008] The copper or copper nickel alloy shapes protect wooden articlesfrom rot and borers, protect steel from rusting, aid osmosis protectionin glass reinforced polyester articles and provide a highly durableoxidised surface that inhibits aquatic growth.

[0009] Preferably the shapes are made from a copper nickel alloy.

[0010] The copper nickel alloy oxide does not leach into the sea likecuprous oxide causing damage to the environment but is generally onlyremoved by erosion, which can occur if the article is moving at highspeeds. The copper nickel alloy oxide remains effective on the surfaceof the alloy for a considerable time and the alloy itself thereforewears away very slowly leading to a treatment having a long lifetime, inexcess of six years.

[0011] The copper nickel alloy is preferably Cupronickel 90/10. Thecopper nickel alloy is the effective ingredient of the product andCupronickel 90/10 is most effective in the prevention of aquatic growthwithout adverse effects on the environment. Other copper nickel alloys,such as Cupronickel 70/30, can be useful if increased durability, orother properties, are required, for example for articles moving quicklythrough the water where erosion of Cupronickel 90/10 occurs at anunacceptable level.

[0012] The shapes are preferably interfacing shapes. The interfacingshapes are preferably adapted in use to be secured to the area of thearticle residing underwater such that the shapes substantiallyinterface.

[0013] The interfacing shapes preferably have a thickness of 150 micronsto 500 microns, most preferably 150 microns. The thickness of theinterfacing shapes allows moulding around the shape of the article towhich the interfacing shapes are being secured. The largest diameter ofthe shapes is preferably from 4 mm to 30 mm depending on the endapplication.

[0014] When in position on the area of the article there are preferablygaps between the interfacing shapes, the gaps are preferably less than0.4 mm wide. The gap size is a compromise between a desired small sizethat limits the attachment area for aquatic growth and entry area forborers and the limitations of the processes for creating the gapsbetween the shapes. The gaps between the interfacing shapes areadvantageous as they allow the interfacing shapes to be readily fittedto the shape of the area of the article being covered. Foil materialused previously had to be pressed and rolled to the shape of the area ofthe article to be covered.

[0015] The interfacing shapes preferably have three or more sides. Themost preferable interfacing shapes are hexagons and squares. Sharpcorners are not desirable as they may interrupt the laminar flow ofwater creating drag and will be susceptible to damage; hexagons andsquares are therefore ideal in shape.

[0016] Alternatively the shapes may be particulate, for examplesubstantially spherical. The particles are preferably adapted in use tobe secured to the area of the article residing underwater such that eachof the particles contacts or substantially contacts adjacent particles.

[0017] The particles preferably have a diameter of less than 150microns, more preferably less than 100 microns and most preferably lessthan 50 microns.

[0018] In a first aspect the shapes are releasably secured to thecarrier film. The shapes are preferably releasably secured to thecarrier film by an appropriate adhesive. The carrier film is preferablya plastics material capable of adopting concave and convex profileswithout creasing.

[0019] The interfacing shapes are preferably secured to the carrier filmto give rise to a regular pattern of shapes each preferably surroundedby small regular gaps forming a border. The border is preferably no lessthan 0.150 mm and no greater than 0.4 mm wide. The gaps between theinterfacing shapes allow the carrier material bearing the interfacingshapes to be manipulated to fit the area of the article being covered.

[0020] Where particles are used, the particles are preferably releasablysecured to the carrier film to give an even coverage of particles on thefilm.

[0021] The product may be provided in sheet or in strip form. Thecarrier film holds the shapes together during manufacture andinstallation and provides protection for the installed product until itis ready for use.

[0022] The carrier film is preferably standard low density polyethylenemost preferably at 60 microns. The adhesive releasably securing theshapes to the carrier film is preferably an acrylic adhesive.

[0023] In a second aspect the shapes are permanently secured to onesurface of the carrier film. The shapes are preferably permanentlysecured to the surface of the carrier film by an appropriate adhesive,preferably a solvent modified acrylic adhesive.

[0024] The carrier film is preferably a plastics material, morepreferably a waterproof plastics material, capable of adopting concaveand convex profiles without creasing. Most preferably, the carrier filmis a waterproof polyester membrane.

[0025] Alternatively the carrier film may be acrylic foam adhesive. Theshapes adhere permanently to the acrylic foam adhesive by the nature ofthe acrylic foam adhesive. Acrylic foam adhesive is particularly usefulin deep-sea applications.

[0026] The interfacing shapes are preferably secured to the carrier filmto give rise to a regular pattern of shapes each preferably surroundedby small regular gaps forming a border. The border is preferably no lessthan 0.150 mm and no greater than 0.4 mm wide. The gaps between theinterfacing shapes allow the carrier material bearing the interfacingshapes to be manipulated to fit the area of the article being covered.

[0027] Where particles are used, the particles are preferably secured tothe carrier film to give an even coverage of particles on the film.

[0028] The product may be provided in sheet or in strip form.

[0029] The carrier material is most preferably provided with an adhesiveon the surface not bearing the interfacing shapes. The adhesive ispreferably a solvent modified acrylic adhesive. The surface bearing theadhesive is preferably covered by a removable backing strip, whichprotects the adhesive until it is ready for use.

[0030] The provision of a carrier material to which the shapes arepermanently secured and which is preferably provided with an adhesivesurface allows easy application of the product to an article.

[0031] In the second aspect a protective film may be releasably secured,preferably by an appropriate adhesive, to the surface of the productbearing the shapes to protect the shapes during manufacture andinstallation. The protective film is preferably standard low densitypolyethylene most preferably at 60 microns. The adhesive releasablysecuring the protective film to the shapes is preferably acrylicadhesive.

[0032] The carrier film bearing interfacing shapes is preferably madefrom an appropriate carrier film material having a continuous film ofcopper or a copper nickel alloy secured thereto by a suitable adhesive,depending on whether the shapes are secured releasably or permanently tothe carrier film. The interfacing shape pattern is preferably created bychemically etching the un-required copper nickel material with aHydrochloric Acid based etching solution, (etchant), most preferablyusing either an acid resistant ink mask or dry film photo-resist. Theacid resistant ink mask or dry film photo-resist has the desired patterndeveloped into it, and is employed to cover the copper or copper nickelalloy to remain secured to the carrier film whilst the Hydrochloric Acidbased chemically dissolves the unprotected metallic materials.

[0033] Alternatively the interfacing shape pattern may be created byacid etching, most preferably using an epoxy acid resist to cover thecopper or copper nickel alloy to remain secured to the carrier film andan acid to remove the unwanted material.

[0034] It may also be possible to make the product by processes such aspressing, stamping, rolling, grinding, electrical-laser processes ormilling.

[0035] The product comprising a carrier material bearing particles ofcopper or copper nickel alloy is preferably made by applying theparticles to a surface of the carrier film coated with appropriateadhesive, depending on whether the particles are releasably orpermanently secured to the film. Excess non-adhered particles arepreferably removed from the carrier film by vibration of the film. Theparticles are most preferably applied to the carrier film as it isunrolled from a first roller and re-rolled onto a second roller.

[0036] The carrier material is extremely flexible and the product cantherefore readily be used to treat areas of the article having sharpedges or tight contours.

[0037] Also provided by the present invention is a method of treating anarea of an article residing underwater comprising applying a pluralityof shapes formed from copper or a copper nickel alloy secured to acarrier film to the area of the article residing underwater such thatthe shapes contact or substantially contact each other.

[0038] In a first aspect the shapes are applied to the area of thearticle in sheet form, releasably secured to a carrier film, mostpreferably by an adhesive. The use of sheet material makes the shapeseasier to install.

[0039] The sheets of shapes may be applied directly to the area of thearticle to be covered. Preferably the area of the article to be coveredis coated with a suitable adhesive system, for example an epoxy primerfollowed by an epoxy adhesive using a brush, roller or spraying means.The epoxy adhesive is preferably based on a bisphenol A epoxy resinreacted with an adducted polyamine to give a flexible cure. The adhesivesystem provides additional protection against rot, rust, borers andosmosis in addition to securing the shapes to the area of the article tobe covered.

[0040] The sheets of shapes are preferably pressed into the adhesivesystem with the shapes contacting the adhesive system. A roller may beused to apply pressure to the sheets to ensure adhesion.

[0041] Once the adhesive system has cured the carrier film may be peeledoff leaving the area of the article covered with a plurality of shapesthat contact or substantially contact each other.

[0042] The shapes may alternatively be applied to areas of articlesbeing made by moulding. Preferably the sheets of shapes are positionedwithin the mould with the shapes facing into the mould. The sheets ofshapes may be held in position by an adhesive, preferably a heat orpressure activated adhesive. The use of a heat or pressure activatedadhesive allows any necessary repositioning of the sheets before theadhesive is activated.

[0043] The shapes facing into the mould are preferably coated with asuitable adhesive system before the moulding process takes place forexample using a brush, a roller or a spray means. Once the mouldingprocess is complete the mould is removed leaving the sheets of shapesadhered to the moulded article, the carrier film is preferably thenpeeled off leaving the area of the article covered with shapes.

[0044] The area of the article may be treated with the productcomprising the carrier film bearing the interfacing shapes or with theproduct comprising the carrier film bearing the particles or acombination of both types of product. Most preferably the productcomprising the carrier film bearing the particles is used on areas ofthe article having sharp edges or tight contours and the productcomprising the carrier film bearing the interfacing shapes is used onthe remaining areas of the article to be covered.

[0045] In the second aspect the shapes are applied to the area of thearticle in sheet form, permanently secured to a surface of a carrierfilm, most preferably by an adhesive. The surface of the carrier filmnot bearing the shapes is preferably provided with an adhesive,preferably covered by a protective film. The use of sheet material,preferably having an adhesive surface makes the product easier toinstall.

[0046] The sheets of shapes may be applied directly to the area of thearticle to be covered. Preferably the area of the article to be coveredis cleaned thoroughly to leave a good surface to which the product canbe applied.

[0047] The adhesive surface of the carrier film is preferably pressedonto the article with the shapes facing away from the article. A rollermay be used to apply pressure to the sheets to ensure adhesion.

[0048] Any protective film covering the product may be peeled offleaving the area of the article covered with a plurality of shapes thatcontact or substantially contact each other.

[0049] The shapes may alternatively be applied to areas of articlesbeing made by moulding. Preferably the sheets of shapes are positionedwithin the mould with the shapes facing into the mould. The sheets ofshapes may be held in position by an adhesive, preferably a heat orpressure activated adhesive. The use of a heat or pressure activatedadhesive allows any necessary repositioning of the sheets before theadhesive is activated.

[0050] Any protective film covering the adhesive surface of the carrierfilm is removed. Once the moulding process is complete the mould isremoved leaving the sheets of shapes adhered to the moulded article, anyprotective film covering the shapes is preferably then peeled offleaving the area of the article covered with shapes.

[0051] The area of the article may be treated with the productcomprising the carrier film bearing the interfacing shapes or with theproduct comprising the carrier film bearing the particles or acombination of both types of product.

[0052] In each aspect of the invention the gaps between the shapes arepreferably grouted, most preferably an epoxy grout is used.

[0053] The present invention further provides an article having an arearesiding underwater wherein the area is coated with a plurality ofshapes formed from copper or a copper nickel alloy and wherein theshapes are arranged on the area of the article such that they contact orsubstantially contact each other.

[0054] The material of the present invention and the way in which it isused will now be described by means of example only with reference tothe drawings in which:

[0055]FIG. 1 shows a plan view of a product of the present invention;

[0056]FIG. 2 shows a plan view of an alternative product of the presentinvention;

[0057]FIG. 3 shows a cross section through a product of the first aspectof the invention; and

[0058]FIG. 4 shows a cross section through a product of the secondaspect of the invention.

[0059]FIG. 1 shows a plan view of the product 1 of the presentinvention. The product 1 comprises a carrier film 2 and a plurality ofhexagons 3 of Cupronickel 90/10 alloy secured to the carrier film 2.

[0060] Cupronickel 90/10 alloy has the composition: Carbon 0.05 maximumCobalt 0.1 maximum Iron 1.0-2.0 Manganese 0.5-1.0 Nickel  9.0-10.0Phosphorus 0.02 maximum Lead 0.02 maximum Sulphur 0.05 maximum Tin 0.03maximum Zinc 0.5 maximum Impurities 0.2 maximum Copper remainder

[0061] The hexagons 3 are laid out in rows on the carrier film 2 witheach row being displaced by half a hexagon when compared with theadjacent row. The hexagons 3 are spaced apart from each other by amaximum of 0.4 mm in any direction which gives rise to a border 4 aroundeach hexagon 3. The hexagons 3 have a width (w) of 5 mm from one side tothe opposing side and a thickness of 0.150 mm.

[0062]FIG. 2 shows a plan view of an alternative product 5 of thepresent invention. The product 5 comprises a carrier film 2 and aplurality of spherical particles 7 of Cupronickel 90/10 alloy(composition given above) secured to the carrier film 2. The particles 7are secured to the carrier film 2 by means of an appropriate adhesive.

[0063] The particles 7 are laid out in randomly on the carrier film 2with each particle contacting or substantially contacting adjacentparticles. The particles 7 are spaced apart from each other by a maximumof 0.4 mm in any direction. The particles 7 have a diameter (d) of 0.150mm.

[0064] The product 1 is made from a carrier film 2 having a continuousfilm of Cupronickel 90/10 secured thereto as described below. Theinterfacing shape pattern is created by chemically etching theun-required copper nickel material with a Hydrochloric Acid basedetching solution (etchant) using either an acid resistant ink mask ordry film photo-resist which has the desired pattern developed into it.The etchant masks used are compatible with the epoxy resins andadhesives used to secure the material 1 of the invention to an article,in the present example the article is the hull of a ship.

[0065] The product 5 is made by unrolling the carrier film 2 from a rolland exposing the side of the carrier film 2 bearing the adhesive tosecure the shapes to the carrier film to particles 7 of Cupronickel90/10. The particles 7 are sprinkled on the side of the carrier film 6bearing the adhesive under the influence of gravity alone. Excessnon-adhered particles 7 are removed from the carrier film 2 by vibrationof the film 6. The film coated with particles 7 is then re-rolled andstored ready for use

[0066] In the remainder of the description of FIGS. 3 and 4 thereference to hexagons 3 should be construed to include particles 7.

[0067] In the first aspect of the invention, shown in FIG. 3, thecarrier film 2 is formed from standard low density polyethylene at 60microns and has an acrylic adhesive on one surface 2 a which isformulated to hold the hexagons 3 on the film 2 during the manufacturingand installation processes.

[0068] In the second aspect of the invention, shown in FIG. 4, thecarrier film 2 is formed from a waterproof polyester membrane and has asolvent modified acrylic adhesive on one surface 2 a, which isformulated to hold the hexagons 3 on the film 2. The other surface 2 bof the film 2 is provided with a solvent modified acrylic adhesive tosecure the product to an article. A protective film 10 manufactured fromstandard low density polyethylene is provided and releasably secured tothe hexagons 3 by acrylic adhesive. A protective film 11 is provided andreleasably secured to the surface 2 b provided with adhesive to protectthe adhesive until the product is to be used.

[0069] The products of the present invention can be applied to existingship hulls to prevent the need for future antifouling and can also befitted to new ship hulls as they are manufactured.

[0070] To apply the products 1, 5 to an existing hull of a ship the samemethod is used with each product.

[0071] In the first aspect the hull is first prepared by cleaning toremove all existing aquatic growth. An epoxy primer is applied to thehull by brush to a level of 60 mm above the loaded water line. When theprimer has cured an epoxy adhesive is applied to the primed hull bybrush. The product 1, 5 is then applied to the hull in sheet form withthe Cupronickel 90/10 shapes 3, 7 contacting the adhesive on the hull.Pressure is applied by roller to ensure that the shapes 3, 7 are forcedonto the adhesive on the hull. Once the adhesive has cured the carrierfilm 2 can be removed by peeling it away from the shapes 3, 7 to leavethe hull of the ship covered in shapes 3, 7 of Cupronickel 90/10 thatcontact or substantially contact each other.

[0072] When applying the products 1, 5 to new build ships having mouldedhulls the moulds are prepared as normal. A marine architect can be usedto provide plans showing how the sheets of product 1, 5 must be cut andpositioned in the mould to give total coverage of the hull.

[0073] The prepared mould is coated with a low tack heat sensitiveadhesive, which allows the sheets of product 1, 5 to be positioned,repositioned if necessary and held in position within the mould with thecarrier film 2 contacting the adhesive. Once the sheets of product 1, 5are correctly positioned a low heat source is applied and the sheets ofproduct 1, 5 are pressed into the mould using a roller.

[0074] An epoxy primer is then applied to the exposed face of theproduct 1, 5, i.e. the Cupronickel 90/10 shapes 3, 7, by brush andallowed to cure following which an epoxy adhesive is applied. The hullis then prepared by moulding in a typical fashion.

[0075] When the hull moulding is finished it is withdrawn from themould. Water can be used to facilitate removal of the hull from themould. The carrier film 2 can then be peeled off to leave a new mouldedhull coated with shapes 3,7 of Cupronickel 90/10 alloy that contact orsubstantially contact each other.

[0076] In treating existing or new ship hulls the product 5 bearing theparticles 7 of Cupronickel 90/10 alloy is generally applied to areas ofthe hull having sharp edges or tight contours. The use of the particles7 adhered to the carrier film 6 allows the product 5 to be flexible andmore easily used in these areas. The product 1 bearing the interfacinghexagons 3 adhered to the carrier film 2 is generally applied to largerand more easily accessible areas of the ship hull.

[0077] In the second aspect the hull is first prepared by cleaning toremove all existing aquatic growth. The product 1, 5 is then applied tothe hull in sheet form by removing the protective film 11 to expose thesolvent modified acrylic adhesive on the surface 2 b and applying theproduct to the hull with adhesive surface 2 b contacting the hull.Pressure is applied by roller to ensure that the sheets of shapes 3, 7are secured by adhesive to the hull. The protective film 10 can then beremoved by peeling it away from the shapes 3, 7 to leave the hull of theship covered in shapes 3, 7 of Cupronickel 90/10 that contact orsubstantially contact each other.

[0078] When applying the products 1, 5 to new build ships having mouldedhulls the moulds are prepared as normal. A marine architect can be usedto provide plans showing how the sheets of product 1, 5 must be cut andpositioned in the mould to give total coverage of the hull.

[0079] The prepared mould is coated with a low tack heat sensitiveadhesive, which allows the sheets of product 1, 5 to be positioned,repositioned if necessary and held in position within the mould with thecarrier film 2, 6 contacting the adhesive. Once the sheets of product 1,5 are correctly positioned a low heat source is applied and the sheetsof product 1, 5 are pressed into the mould using a roller.

[0080] The protective sheet 11 is removed from the surface 2 b of thecarrier film to expose the solvent modified adhesive. The hull is thenprepared by moulding in a typical fashion.

[0081] When the hull moulding is finished it is withdrawn from themould. Water can be used to facilitate removal of the hull from themould. The protective film 10 can then be peeled off to expose shapes 3,7 and leave a new moulded hull coated with shapes 3, 7 of Cupronickel90/10 alloy that contact or substantially contact each other.

1. A product for the treatment of an area of an article residingunderwater, said product comprising a plurality of shapes formed fromcopper or a copper nickel alloy and a carrier film and adapted in use tobe secured to the area of the article residing underwater such that theshapes substantially contact each other.
 2. A product according to claim1 wherein the shapes are copper nickel alloy shapes.
 3. A productaccording to claim 2 wherein the copper nickel alloy is Cupronickel90/10.
 4. A product according to claim 1 wherein the shapes have athickness of 150 microns to 500 microns.
 5. A product according to claim4 wherein the shapes have a thickness of 150 microns.
 6. A productaccording to claim 1 wherein the largest diameter of the shapes is from4 mm to 30 mm.
 7. A product according to claim 1 wherein, when inposition on the area of the article, there are gaps between the shapes,not greater than 0.4 mm wide.
 8. A product according to claim 1 whereinthe shapes are interfacing shapes.
 9. A product according to claim 1wherein the shapes are particulate.
 10. A product according to claim 9wherein the particles have a diameter of less than 150 microns.
 11. Aproduct according to claim 1 wherein the shapes are releasably securedto the carrier film.
 12. A product according to claim 11 wherein thecarrier film is a plastics material capable of adopting concave andconvex profiles without creasing.
 13. A product according to claim 11wherein the carrier film is standard low density polyethylene.
 14. Aproduct according to claim 11 wherein the shapes are secured to thecarrier film by an acrylic adhesive.
 15. A product according to claim 1wherein the shapes are permanently secured to one surface of the carrierfilm.
 16. A product according to claim 15 wherein the shapes arepermanently secured to the surface of the carrier film by a solventmodified acrylic adhesive.
 17. A product according to claim 15 whereinthe carrier film is a waterproof plastics materials capable of adoptingconcave and convex profiles without creasing.
 18. A product according toclaim 17 wherein the carrier film is a waterproof polyester membrane.19. A product according to claim 15 wherein the carrier material has anadhesive on the surface not bearing the shapes.
 20. A product accordingto claim 19 wherein the adhesive is a solvent modified acrylic adhesive.21. A product according to claim 15 wherein a protective film isreleasably secured to the surface of the product bearing the shapes toprotect the shapes during manufacture and installation.
 22. A productaccording to claim 15 wherein the carrier film is acrylic foam adhesive.23. A product according to claim 1 wherein the product is provided insheet or strip form.
 24. A method of making the product of claim 1, saidmethod comprising providing a carrier film material having a continuousfilm of copper or a copper nickel alloy secured thereto, and creating aplurality of substantially contacting shapes by chemically etching theun-required copper nickel material with an acid based etching solution.25. A method of treating an area of an article residing underwater, saidmethod comprising applying a plurality of shapes formed from copper or acopper nickel alloy secured to a carrier film to the area of the articleresiding underwater such that the shapes substantially contact eachother.
 26. A method according to claim 25 wherein the shapes arereleasably secured to the carrier film.
 27. A method according to claim26 wherein the area of the article to be covered is coated with asuitable adhesive system, sheets of shapes are pressed into the adhesivesystem with the shapes contacting the adhesive system, and the carrierfilm is peeled off leaving the area of the article covered with aplurality of shapes that substantially contact each other.
 28. A methodaccording to claim 26 further comprising positioning the sheets ofshapes within a mould with the shapes facing into the mould, coating theshapes facing into the mould with a suitable adhesive system, performingthe moulding process, removing the mould, leaving the sheets of shapesadhered to the moulded article, and peeling off the carrier film,leaving the area of the article covered with shapes.
 29. A methodaccording to claim 25 wherein the shapes are permanently secured to asurface of a carrier film and the surface of the carrier film notbearing the shapes is adhesive.
 30. A method according to claim 29wherein the adhesive surface of the carrier film is pressed onto thearticle with the shapes facing away from the article leaving the area ofthe article covered with a plurality of shapes that substantiallycontact each other.
 31. A method according to claim 29 furthercomprising positioning the sheets of shapes within a mould with theadhesive surface of the carrier film facing into the mould, performingthe moulding process, and removing the mould, leaving the area of thearticle covered with shapes that substantially contact each other. 32.The method of claim 25 further comprising applying grout to the gapsbetween the shapes.
 33. An article having an area residing underwaterwherein the area is coated with a plurality of shapes formed from copperor a copper nickel alloy and wherein the shapes are arranged on the areaof the article such that they substantially contact each other.
 34. Amethod according to claim 24, further comprising providing gaps, notgreater than 0.4 mm, between the shapes.
 35. A method according to claim25, further comprising providing gaps, not greater than 0.4 mm, betweenthe shapes.
 36. A method according to claim 27, further comprisingproviding gaps, not greater than 0.4 mm, between the shapes.
 37. Amethod according to claim 30, further comprising providing gaps, notgreater than 0.4 mm, between the shapes.
 38. A method according to claim31, further comprising providing gaps, not greater than 0.4 mm, betweenthe shapes.
 39. An article according to claim 33 wherein the shapes havegaps not greater than 0.4 mm between them.